Phenol aldehyde-petroleum pitchdrying oil impregnating composition



Patented Oct. 18, 1949 PHENOL ALDEHYDE-PETROLEUM PITCH- DRYING OIL IMPREGNATING COMPOSI- TION Howard Snow, Charlotte, N. 0., assignor to Southern Friction Materials Company, a corporation of North Carolina No Drawing. Application September 27, 194.6, Serial No. 699,641

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1 I This invention relates to an impregnating chemical composition that isespecially adapted for impregnating woven textile fabric. This is a continuation-in-part of my copending application Serial No. 490,877, filed June 15, 1943, now

abandoned. I

The composition of the present invention 1mparts to the fabric a markedly high water and wear resistance, rendering it suitable for use as shoe sollng, floor covering, and other s1m1lar applications, especially-when the impregnated prodnot is surface finished as described in my copending application Serial No. 467,620, filed December 2, 1942; now U; S. Patent 2,42L86l. Because of the chemical nature of this composition and the incorporation thereof inthe fabric in unusually large quantities, the resulting, impregnated product has new and advantageous characteristics that render it especially adaptable for use as a leather substitute and. the like.

The percent solids content of my composition may vary substantially with diiierent uses. However, when the composition is employed for 1mpregnating fabric to produce a leather subst1 tute, I have foundit advantageous. to utilize a high percentage, such as for example 60% to,90% solids, by weight. A composition of suchv solids content generally requires heating to obtain easy handling and impregnation of fabrics therewith but it makes it possible for the fabric to attain the high pick-upor gain in weight which is required to produce the improved artificial leather productsoi my invention.

Certain unique and outstandnig characteristics of my composition-, especially for imparting water andwear resistance to fabrics, result from the combination. of several compatible chemical substances that. coact with each other. The properties of each constituent complement those of the other constituents with regard to stability, plasticity of flexibility, water repellance and wear resistance; all of which are desired for the commercial uses of my composition. These and other desirable features are provided fundamentally by a combination of an oil soluble thermosetting resin, mineral oil polymers, a, drying oil, and a suitable organic solvent.

In this combination, the thermosetting resin. provides the desired hardness and wear resistance that. characterize my. product. Suitable resins for this component of the composition are the phenolic resins, e. g.. phenol,-formaldehyde resins such as are identified in the trade, as Durite 1301,

Amberol' STl'37', and Durez 11.696; modified.

hydemodified with rosin, such as Amberol M--93,

or ester gum modified phenol formaldehyde, suchas Phenac 622.14; and oil modified phenolic resins, such as Bakelite 17932 which is an oil modified phenol-formaldehyde resin. Also, resins such. as ester gum may be used, which are formed by combinin a resinofacid nature, such as rosin, with phenol or an alcohol such as glycerol.

For augmenting the penetrating characteristics: of the composition and increasing its afli'nity for the treated material, an unsaturated viscous liquid of petroleum origin, which is sometimes referred to in the trade as petroleum pitch, and which is identified hereafter as mineral oil polymers, isemployed. An illustrative example of the latter is Pur-O-Resin 21 38 which has the following published characteristics: gravity 60/60 F., 0.993; A. P. I. gravity a-p prox.), 11; viscosity Saybolt Universal at 210' E, 275-325; pour point, min. solid content (A. S. 'I'. M. D-l'54-28), 90% min.; iodine number (Wijs modified), 200 min.; saponification number, 1.0 max., beginning boiling range, 450 F; This material is reactive with drying oils and is composed of polymerized olefinic hydrocarbons;

To provide the desired flexibility and tensile strength in the treated material, and to modify somewhat the hardness properties of the resins, the composition also contains as a major constituent, a drying or semi-dryin oil. A commerciallyadvantageous example of such an oil is linseed oil. Other examples of suitable drying oils which may be used are, China-wood oil, oiticica oil, perilla oil, soya bean oil, dehydrated castor oil, cashew-nut shell oil, and syntheticdrying oils I such as Highland G oil which has the followphenol aldehyde resins, e.. g. phenol-formaldemg characteristics; viscosity G (G and H); specifiic gravity 0.977; iodine value 0.145; saponification value 215; derivative of native linseed oil with the break removed; temperature tolerance and resin tolerance equal to linseed oil. 'Ihisoil' may advantageously be combined with linseed oil or other drying or-semi-drying oils for use in my composition.

Another synthetic drying oil which may be used in my composition is Hyodol Glycerides, which is obtained by splitting the glycerine from fish oil, such. as sardine oil, followed by fractionating the fish oil acids and finally reesterifying the fraction consisting partially of clupanodonic acid. The resulting product, Hyodol Glycerides, is. the glyceride of clupanodonic acid and similar highly unsaturatedfatty acids. It is. characterizedby an acid number of about 5- to 8, iodine number of 214 to 220 and viscosity (Gardner) A-B. For sake of convenience this product will be referred to hereafter as clupanodonic glyceride." It is especially useful in my composition in combination with linseed oil, to augment the water repellent-properties of the composition. Furthermore, this product is compatible with the other oils and resins used in my composition and has an especial afiinity for combining with th mineral oil polymers. A commercially advantageous combination for purposes of my invention is a mixture of linseed oil and clupanodonic glyceride to provide the water repellent drying oil constituent of my impregnating composition.

In addition to the drying oil properties provided by the clupanodonic glyceride, it also possesses certain plasticizing properties that render the hard resin or gum constituent lessv brittle and therefore more flexible and suitable for impregnating material which is to be used for shoe soles or other substitute leather products that require-flexing properties in their regular use. Where greater flexibility and plasticity are required for the composition, in preference to increased hardness, a portion of the hard resin or gum in my composition may be replaced by the clupanodonic glyceride or by another suitable synthetic drying oil, such as for example the above mentioned Highland G or modified linseed oil.

To obtain the desired fluidity and thinness of the composition, a suitable organic solvent or thinner is incorporated. These materials are generally identified as mineral spirits solvents, of which petroleum distillate solvents are a good example. Coal tar distillate solvents may also be employed. Examples of suitable commercial solvents are xylol; benzol; and the petroleum thinners, Varsol and Solvesso Amsco Spirits and VM&P solvent. All of these trade-marked products are well known, light petroleum dis- Example III Parts Thermosetting resin or gum, e. g., Bakelite ' Mineral oil polymers, e. g., Pur-0-Resin 30 tillates and are widely available in commercial quantities.

The following illustrative but non-limiting examples of my impregnating composition show some of the specific, alternative, combinations of constituents that may be used for producing different types of impregnated products, or for different manufacturing procedures:

Example I Pounds Thermosetting resin or gum e. g., ester gum 20' The procedure used for preparation of the compositions disclosed in Examples I and II above is as follows: The thermosetting gum or resin, mineral oil polymers, and drying oil, are heated together to a suitable temperature which may vary from about 300 F. to about 550 F. depending upon the exact types of constituents used. The heating is continued until the resin or gum, mineral oil polymers and drying oil react and com- Drying oil, e. g.:

Boiled linseed 20 Cicoil 25 Solvent, e. g., mineral spirits 75 Driers, e. g.: 6% iron naphthenate 0.25 8% zinc naphthenate 0.05 6% manganese naphthenate 0.03

The boiled linseed oil and Pur-O-Resin are mixed and heated to 400 F. The mix is then checked to 350 F. with cicoil, and the Bakelite" resin is added and the temperature is held at 350 F. until the resin is melted in and mixed well. Then, 10 to 20 parts of solvent are added, after which the composition is allowed to cool while the remaining solvent and driers are added. The resulting composition has a specific gravity of about .875 at 110 F. 1

Example IV v Parts Thermosetting resin or gum, e. g., Pen- The cicoil, boiled linseed, and Pur-O-Resin are mixed and heated to 300-F. The resin is then added and the temperature is increased to 400 F. and held until the proper viscosity is reached. 10-20 parts of solvent are added, and the composition is allowed to cool while the remaining solvent and driers are added. The specific gravity of the resulting composition is about .875 at 110 F., as above.

The weight of the complete, penetrative, impregnating composition that is absorbed by the fabric during the treatment will vary from 50% to of the original dry weight of the untreated fabric. And these percentages correspond generally to 35% to 50% of impregnant solids in the finished product after removal of volatiles.

It will be understood that the composition of my invention is not limited to the manufacture of artificial leather or the like, but may be used for any and all of the general impregnating applications to provide a water resistant and wear resistant substance. The basic features of the composition of my invention comprise the above described combination of an oil soluble thermosetting resin, or gum, mineral oil polymers, drying oil and solvent. The ranges of proportions of these several constituents are illustrated by the following;

Ingredients: Parts by weight Thermosetting resin or gum 1 /2-2 Mineral oil polymers 3-4 Drying oil 45 /2 Solvent 1 7 /2 Usually it is preferable to use a high solvent proportion because of the better penetration obtained and employ a two-dip treating proces for impregnating although the solvent percentage may be lowered if desired, as noted above, to condition the composition for a single-dip treatment process.

I claim:

1. A liquid composition for impregnating fabric to render it water and wear resistant comprising: the thermosetting heat reaction products of, an oil-soluble resin reselected from the group consisting of phenol-aldehydes, oil-modified phenolaldehydes, and rosin ester-modified phenol-aldehydes, petroleum pitch composed of polymerized olefinic hydrocarbons and having a minimum iodine number of about 200 and a boiling range beginning at 450 F., and a drying oil; and a petroleum distillate solvent; the proportions by weight of said constituents being 1% to 2 parts of said resin, 3 to 4 parts of said pitch, 4 to 5 /2 parts of said drying oil, and 1 to 7 /2 parts of said solvent.

2. The method of preparing a composition as defined in claim 1, comprising heating together the oil-soluble resin, petroleum pitch, and drying oil constituents at a temperature of about 300 F.

to 550 F. for a sufiicient length of time to effect a reaction between the constituents and render the composition more viscous than it was before heating, and then mixing the reacted composition with said solvent.

3. A liquid composition for impregnating fabric to render it water and wear resistant comprising: the thermosetting heat reaction products of, an oil modified phenol formaldehyde resin, petroleum pitch composed of polymerized olefinic hydrocarbons and having a minimum iodine number of about 200 and a boiling range beginning at 450 F., and a dryin oil; and a petroleum distillate solvent; the proportions by weight of said constituents being 1 /2 to 2 parts of said resin, 3 to 4 parts of said pitch, 4 to 5 parts of said drying oil, and 1 to 7 /2 parts of said solvent.

4. The method of preparinga composition as defined in claim 3, comprising heating together I and render the composition more viscous than it was before heating, and then mixing the reacted composition with said solvent.

5. A liquid composition for impregnating fabric to render it water and wear resistant comprising: the thermosetting heat reaction products of, phenol formaldehyde, petroleum pitch composed of polymerized olefim'c hydrocarbons and having a minimum iodine number of about 200 and a boiling range beginning at 450 F., and a drying oil; and a petroleum distillate solvent; the proportions by weight of said constituents being 1 to 2 parts of said resin, 3 to 4 parts of said pitch, 4 to 5 parts of said drying oil, and 1 to 7 parts of said solvent.

6. A liquid composition for impregnating fabric to render it water and wear resistant comprising: the thermosetting heat reaction products of, rosin ester, modified phenol formaldehyde resin, petroleum pitch composed of polymerized olefinic hydrocarbons and having a minimum iodine number of about 200 and a boiling range beginning at 450 F., and a drying oil; and a petroleum distillate solvent; the proportions by weight of said constituents being 1 to 2 parts of said resin, 3 to 4 parts of said pitch, 4 to 5% parts of said drying oil, and l to 7 parts of said solvent.

'7. A liquid composition for impregnating fabric to render it wear and water resistant comprising: the thermosetting heat reaction products of, an oil-soluble resin selected from the class consisting of phenol-aldehydes, oil-modified phenolaldehydes, and rosin ester-modified phenol-aldehydes, petroleum pitch composed of polymerized olefinic hydrocarbons and having a minimum iodine number of about 200 and a boiling range beginning at 450 F., and a drying oil; and an organic solvent selected from the class consisting of petroleum distillate solvents and coal tar distillate solvents; the proportions by weight of said constituents being 1 to 2 parts of said resin, 3 to 4 parts of said pitch, 4 to 5 /2 parts of said drying oil, and 1 to 7 /2 parts of said solvent.

8. Ihe method of preparing a composition as defined in claim 7, comprising heating together the oil-soluble resin, petroleum pitch, and drying oil constituents at a temperature of about 300 F. to 550 F. for a sufficient length of time to effect a reaction between the constituents and render the composition more viscous than it was before heating, and then mixing the reacted composition with said solvent.

HOWARD snow.

REFERENCES CITED UNITED STATES PATENTS Name Date Rostler et a1. Mar. 20, 1945 Number Certificate of Correction Patent No. 2,485,327 October 18, 1949 HOWARD SNOW It is hereby certified that errors appear in the printed specification of the above numbered patent requiring correction as follows:

Column 1, line 34, for outstandnig read outstanding; column 5, line 24, for the word reselected read selected;

and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Oflice.

Signed and sealed this 21st day of February, A. D. 1950.

THOMAS F. MURPHY,

Assistant Commissioner of Patents. 

